Stabilization of looped fabric surfaces by fine-scale embossing

ABSTRACT

A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/517,440, filed Jun. 9, 2017, the entire contents of which isincorporated herein by reference.

TECHNICAL FIELD

Embodiments of the subject matter disclosed herein relate to embossinglooped fabrics and textile-faced composite floor-coverings.

BACKGROUND

Cushioning textile fabrics are constructed by weaving, knitting, tuftingor stitch-bonding, with looping surface yarns engaging each other orlooping in and out of a “backing” or “substrate” at intervals having arelatively large spacing. These textile fabrics require stabilization ofthe surface yarns for use in applications requiring high resistance toabrasion and resistance to planar deformation such as flooring,wallcovering and upholstery. Stabilization of the surface can beachieved by inter-bonding yarns throughout the structure or by locallybonding the lower parts of the loops, located away from the surface.However, inter-bonding of the yarns throughout the structure to a degreesufficient to provide abrasion resistance and dimensional stabilityunder severe end use tends to stiffen the surface of the textile fabricand reduce cushion.

As an alternative, the entire backside of the fabric can be bonded withsoft adhesives and optionally attached to various “secondary backings”as in the case of tufted fabrics with the entire backside of the fabricattached adhesively to a backing. While continuous bonding underneathcan stabilize the dimensions and the surface of the fabric againstabrasion, wear issues and edge fraying remain a problem for fabricsformed with yarn loops spaced apart. In particular, the upper parts ofthe loops can still degrade with abrasion. Moreover, at the cut edgesthat are not anchored, relatively long ends of yarns can fray and fuzzduring use.

Regarding continuous bonding of the flat or textured backside of loopedyarn fabrics, effective bonding also requires highly-fluid low-viscosityadhesives. Examples of these highly-fluid low-viscosity adhesivesinclude latexes and polymeric binders and powdered adhesives carried byliquids. Localized activation also requires controlled adhesive flowinto the lower portions of the yarns as well as into and out of thebacking or substrate. This controlled adhesive flow is required to bedirected into the desired portions of the textile fabric withoutcontaminating the exposed loops of the surface yarns. While avoiding theexposed surface yarns, the process of controlled adhesive flow,exemplified by the common use of latex adhesives applied to theback-laps and the backside of the “primary backings” of a tufted fabric,requires the application of a substantial amount of adhesive to reachall surfaces and to achieve strong bonds. This substantial amount ofadhesive stiffens the textile fabric.

As an alternative to controlled adhesive flow, dry adhesives areintroduced into or around the backing or substrate. Dry polymeric lowmelting adhesives tend to have relatively high melt viscosities andrequire high pressures at elevated temperatures to achieve bonding.These high melt viscosities and the associated high bonding pressuresresult in “crushing” of the fabric, the loss of thickness and cushion,and increased planar stiffness. While these results are acceptable andeven desirable for certain types of “hard-surface” floorcoverings orwallcoverings, they are not suitable for soft-faced floor orwallcoverings and for fabrics requiring conformability, such asupholstery.

A new family of cushioning textile-faced composite structures, aimedmainly at floorcoverings or wallcoverings, utilizes a relatively thickcushioning backing placed under and bonded to a thinner fabric facelayer. The fabric face layer may be formed with yarns and can be flat orhighly textured. Moreover, the fabric face layer itself may be texturedafter forming the composite structure, for example, by embossing thedesired texture into the fabric face layer. A highly textured surface isusually formed by embossing patterns extending into the compositestructure to depths exceeding the original thickness of the fabric facelayer. Unless the fabric face layer is severely crushed, collapsed andrigidified across the entire area of the fabric face layer by applyingheat and pressure from the top of the composite, yarns in the fabricface layer are not sufficiently stabilized along their entire lengths.For tufted constructions, looping face yarns, which are placed atrelatively large intervals along the fabric face layer on a “primarybacking”, can easily loosen and can even pull free. For compositestructures that are cut into individual tiles such as modular flooringtiles, these looping face yarns can disintegrate along cut edges and“fuzz” as the upper parts of the sectioned loops remain free and burstopen upon contact.

Deeply-textured embossed patterns on a textile fabric or compositestructure can provide the desired combination of durability, surfacestability and dimensional stability and can add plush-aesthetics,cushion, thermal insulation and better planar conformability. Howeverlooped textile fabrics and composite structures deeply embossed withoutprior stabilization with adhesives fail to achieve the desiredcut-edge-stability in the face yarns. This lack of edge-stabilityresults from the less-compressed “elevated” areas remaining less-bondedor non-bonded as compared to the more compressed “depressed” areas whenthe fabric face layers are directly laminated onto a backing as they areembossed. These elevated and less-compressed areas remain vulnerable towear, abrasion, deterioration, unraveling or “fuzzing”, especially alongcut edges.

Tufted yarns are looped by insertion into a primary backing without theloops engaging each other. The tufted yarns also require larger spacesbetween insertions as compared to knit, stitch-bonded or wovenconstructions. Unless the entire structure under the pile of tuftedyarns, including the “back-laps”, is engaged with and enveloped byadhesive, tufted yarns are subject to tuft pull-out. Therefore, tuftedyarns require the use of significant amounts of adhesive, which renderstufted yarn fabrics unsuitable for flexible stand-alone end uses such asupholstery, and for adoption into composites relying on soft backingsfor cushion. Stand-alone tufted fabrics stabilized with low amounts ofadhesives without stiffening the face pile loops, or the entire fabric,and without the total loss of the looped face appearance, are desirable.

Given the limitations of various types of conventional applications ofyarns, and particularly involving their use as face layers in modularcomposite tile flooring, the need exists for the stabilization offabrics formed with loops of yarns having the desired softness, cushionand wear properties while avoiding wear, abrasion, deterioration, andunraveling or “fuzzing”, especially along cut edges.

SUMMARY

Exemplary embodiments are directed to a method for stabilizing alooped-yarn fabric along the entire surface and along cut edges. Thelooped-yarn fabric is stabilized without causing the loss of a generallylooped surface structure and without severely stiffening the fabric orthe surface loops. The thickness of the original fabric is reduced byapproximately 20 to 60%, preferably by less than 40%. In addition, thefrequency of the loops is increased, and the regularity of the exposedloops is altered. However, the surface of the fabric maintains a loopyappearance.

Exemplary embodiments are also directed to a method for using alooped-yarn fabric stabilized in accordance with embodiments describedherein as a surface layer in composites and floor-coverings that utilizean attached backing layer for cushion. The looped-yarn fabric isattached to the backing layer and used as the surface layer incomposites and floor-coverings without losing the looped characteristicand without severely stiffening the surface loops. In one embodiment,after attachment the thickness of the original looped-yarn fabric isreduced by about 20-60%, preferably by less than 40%, while the overallthickness of the composite changes by a much lower percentage.

In accordance with embodiments described herein, patterns finer and morefrequent than the frequency that the yarn loops into the plane of thefabric are referred to as “micro-patterns”. Deeper and coarser embossingpatterns where the spacing exceeds the original spacing of yarn loopsare referred to as “macro-patterns”. The resulting densely-embossedlooped fabrics or composites have highly-stabilized cut edges andmaintain durability along the entire surface area of the fabric facelayer, including all elevated and depressed areas. Fabrics stabilized bymicro-embossing, i.e., embossing with micro-patterns, with a regular orrandom pattern finer than the pattern of loop repetition contain twosuperimposed patterns, the original pattern of yarn loops and themicro-pattern. These stabilized fabrics are relatively flat.

Fabrics receiving a second regular or random macro-embossing, i.e.,embossing with macro-patterns, after being stabilized with amicro-pattern contain three superimposed patterns and are highlytextured or three-dimensional. In one embodiment, the second andoptional coarser embossing with the macro-pattern is performed with thefabric containing the embossed micro-pattern placed over a soft back-upsurface such as silicon rubber. In one embodiment with a compositecontaining a cushioning backing, the second optional embossing with themacro-pattern is performed directly over the fabric that waspre-embossed with a micro-pattern, i.e., the pre-stabilized-fabric,placed over the cushioning backing before embossing with themacro-pattern and simultaneously attaching it to the backing.

Exemplary embodiments are also directed to a method for using facelayers stabilized in accordance with embodiments described herein in acomposite used as a floor-covering that relies primarily or entirely ona backing layer for providing the desired cushion

Exemplary embodiments are directed to methods for stabilizinglooped-yarn fabrics that use reduced or lower amounts of adhesives tostabilize the fabrics. Suitable looped-yarn fabrics include, but are notlimited to, woven, knit, stitch-bonded and tufted fabrics.

Exemplary embodiments facilitate the use of thinner tufted fabrics inhigh-durability end uses without consuming a high weight of yarns.Tufted fabrics can provide substantial cover but very limited cushion atvery low tufted yarn weights and thin piles. Stabilizing tufted fabricswith relatively low amounts of adhesives while maintaining a looped faceappearance and avoiding stiffening the face structure or the entiresheet with high amounts of adhesives, yields tufted fabrics suitable foruse as durable and abrasion resistant fabrics. These stabilized tuftedfabrics can also be combined with cushioning backing layers to serve asthe face layers of composite floorcoverings, wallcoverings, orupholstery. In addition, thin pile tufted fabrics can be formed withpolyester yarns, which offer durability and resistance to thermal orhygroscopic expansion or contraction, but lack resilience.

Polyester yarns, as opposed to polyolefin or polyamide yarns, whenformed into a pile tend to bend and “mat-down”. This bending and mattingof the polyester yarns results in a loss of cushion and fibrous faceaesthetics. Therefore, the use of ordinary polyester yarns is limited toforming tufted flooring such as in “shag” carpeting where the sidewisebending of the yarns and pile and the consumption of large amounts ofyarn are acceptable. Polyamide yarns such as nylon yarns resist bendingand recover quickly from bending. However, polyamide yarns have a highercoefficient of thermal expansion and tend to be affected by temperatureand moisture. Polyolefin yarns, while not affected by moisture, haveeven higher coefficients of thermal expansion and contraction thanpolyamide yarns. Fabric surfaces formed by tufted nylon or polypropyleneand incorporated into modular or tile flooring require dimensionalstabilization with heavy layers of glass fibers. With a pre-stabilizedflexible and thin tufted fabric, polyester can be used in the flooringcomposites relying upon a soft backing for cushion, without requiringextra stabilization and without negatively affecting the recyclingability of the product.

Exemplary embodiments are directed to a fabric containing a plurality ofyarns forming a plurality of loops, the plurality of loopsinterconnected at a plurality of interlooping points spaced across thefabric by interlooping distances between pairs of interlooping points.In one embodiment, the fabric is a knit fabric or a woven fabric. Thefabric includes an embossed micro-pattern disposed on a first face ofthe fabric. The embossed micro-pattern contains a plurality of bindingpoints extending into the first face and binding the yarns in theplurality of yarns. Adjacent binding points in the plurality of bindingpoints are separated by a binding point distance, and the binding pointdistance is less than the interlooping distances.

In one embodiment, the fabric includes a sub-layer in contact with asecond face of the fabric opposite the first face. The binding points inthe plurality of binding points extend into the sub-layer and interbondthe sub-layer and the yarns. In on embodiment, the fabric is astitchbonded fabric containing a substrate. The interloping points inthe plurality of interlooping points are points of insertion of theplurality of loops into the substrate. The interloping distance is thespacing between the points of intersection in either a first directionacross the fabric or a second direction perpendicular to the firstdirection. The binding points extend into the substrate and interbondthe substrate and the yarns. In one embodiment, the substrate comprisesa low melt material. In one embodiment, the fabric also includes atleast one additional low melt layer disposed between the substrate andat least one of the first face a second face opposite the first face.

In one embodiment, the fabric is a tufted fabric with a primary backing.The interloping points in the plurality of interlooping points are thetufting points through the primary backing. The interlooping distance isthe spacing between the tufting points in either a length direction or awidth direction across the fabric. The binding points extend into theprimary backing and interbond the primary backing and the yarns. In oneembodiment, the primary backing includes low melt components. In oneembodiment, the fabric further includes at least one additional low meltlayer disposed between the primary backing and at least one of the firstface a second face opposite the first face.

In one embodiment, the fabric further includes an embossed macro-patternseparate from the micro-pattern. The macro-pattern has a plurality ofelevated areas and a plurality of depressed areas that establish adesired aesthetic in the fabric. Adjacent elevated areas and adjacentdepressed areas are separate by a spacing interval, and the spacinginterval is greater than the interlooping distances. In one embodiment,the fabric has an initial thickness and an embossed thickness followingapplication of the micro-embossed pattern. The embossed thickness isfrom about 40% to about 80% of the initial thickness. In one embodiment,the fabric has an initial thickness and an embossed thickness followingapplication of the micro-embossed pattern, and the embossed thickness isat least about 60% of the initial thickness. In one embodiment, theyarns in the plurality of yarns include polyester.

Exemplary embodiments are also directed to a textile compositecontaining a fabric having a plurality of yarns forming a plurality ofloops. The loops in the plurality of loops are interconnected at aplurality of interlooping points spaced across the fabric byinterlooping distances between pairs of interlooping points. The fabricalso includes an embossed micro-pattern disposed on a first face of thefabric. The embossed micro-pattern includes a plurality of bindingpoints extending into the first face and binding yarns in the pluralityof yarns. Adjacent binding points in the plurality of binding points areseparated by a binding point distance, and the binding point distance isless than the interlooping distances. The textile composite alsoincludes a cushioning backing attached to a second face of the fabricopposite the first face using adhesive.

In one embodiment, the fabric is a knit fabric or a woven fabric, andthe fabric also includes a sub-layer in contact with the second face ofthe fabric. The binding points in the plurality of binding points extendinto the sub-layer and interbond the sub-layer and the yarns. In oneembodiment, the fabric is a stitchbonded fabric containing a substrate.The interloping points in the plurality of interlooping points arepoints of insertion of the plurality of loops through the substrate. Theinterloping distance is the spacing between the points of intersectionin either a length direction or a width direction across the fabric. Thebinding points extend into the substrate and interbond the substrate andthe yarns. In one embodiment, the fabric is a tufted fabric having aprimary backing. The interloping points in the plurality of interloopingpoints are the tufting points through the primary backing. Theinterloping distance is the spacing between the tufting points in eithera length direction or a width direction across the fabric. The bindingpoints extend into the primary backing and interbond the primary backingand the yarns.

In one embodiment, the textile composite also includes an embossedmacro-pattern separate from the micro-pattern. The macro-pattern has aplurality of elevated areas and a plurality of depressed areas thatestablish a desired aesthetic in the textile composite. Adjacentelevated areas and adjacent depressed areas are separate by a spacinginterval, and the spacing interval greater than the interloopingdistances.

Exemplary embodiments are also directed to a method for stabilizing afabric. A fabric is formed with a plurality of yarns forming a pluralityof loops. The loops in the plurality of loops are stabilized orinterconnected at a plurality of interlooping points spaced across thefabric by interlooping distances between pairs of interlooping points. Afirst face of the fabric is embossed with a micro-pattern having aplurality of binding points extending into the first face and bindingyarns in the plurality of yarns. Adjacent binding points in theplurality of binding points are separated by a binding point distance,and the binding point distance less than the interlooping distances. Inone embodiment, the fabric containing the micro-pattern is embossed witha macro-pattern separate from the micro-pattern. The macro-pattern has aplurality of elevated areas and a plurality of depressed areas thatestablish a desired aesthetic in the fabric. Adjacent elevated areas andadjacent depressed areas are separated by a spacing interval, and thespacing interval greater than the interlooping distances.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate one or more embodiments and,together with the description, explain these embodiments. In thedrawings:

FIG. 1 is a schematic representation of a cross-section of an embodimentof a looped fabric;

FIG. 2 is a schematic representation of the looped fabric of FIG. 1calendered flat with heat to bond the surface loops;

FIG. 3 is a schematic representation of a cross-section of the fabric ofFIG. 1 embossed with a micro-pattern;

FIG. 4 is a schematic representation of a first face of a looped fabricembossed with a micro-pattern;

FIG. 5 is a schematic representation of a cross-section of the loopedfabric of FIG. 1 embossed with a macro-pattern;

FIG. 6 is a schematic representation of a cross-section of the loopedfabric of FIG. 3 embossed with a macro-pattern;

FIG. 7 is a schematic representation of a macro-pattern;

FIG. 8 is a view through line 8-8 of FIG. 7;

FIG. 9 is a schematic representation of a cross-section of an embodimentof a stitch-bonded fabric;

FIG. 10 is a schematic representation of a cross-section of thestitch-bonded fabric of FIG. 9 embossed with a micro-pattern;

FIG. 11 is a schematic representation of a cross-section of anembodiment of a tufted fabric;

FIG. 12 is a schematic representation of the tufted fabric of FIG. 11embossed with a micro-pattern;

FIG. 13 is a schematic representation of a cross-section of a textilecomposite of a looped fabric placed over an adhesive layer and acushioning backing;

FIG. 14 is a schematic representation of the textile composite of FIG.13 embossed and laminated to produce a macro-pattern;

FIG. 15 is a schematic representation of a textile composite formed byembossing and laminating with a micro-pattern;

FIG. 16 is schematic representation of the textile composite of FIG. 18post-embossed with a macro-pattern;

FIG. 17 is a flow chart illustrating an embodiment of a method forstabilizing a looped yarn fabric or textile composite; and

FIG. 18 is a flow chart illustrating another embodiment of a method forstabilizing a looped yarn fabric or textile composite.

DETAILED DESCRIPTION

The following description of the embodiments refers to the accompanyingdrawings. The same reference numbers in different drawings identify thesame or similar elements. The following detailed description does notlimit the invention. Instead, the scope of the invention is defined bythe appended claims.

Reference throughout the specification to “one embodiment” or “anembodiment” means that a particular feature, structure or characteristicdescribed in connection with an embodiment is included in at least oneembodiment of the subject matter disclosed. Thus, the appearance of thephrases “in one embodiment” or “in an embodiment” in various placesthroughout the specification is not necessarily referring to the sameembodiment. Further, the particular features, structures orcharacteristics may be combined in any suitable manner in one or moreembodiments.

Referring initially to FIG. 1, a looped yarn fabric 100 includes aplurality of yarns 107 that form a plurality of interlooping loopsextending along and across the looped yarn fabric. Suitable yarnsinclude, but are not limited to, polyamide or nylon, polypropylene,polyolefin, acrylic, polyester, wool and cotton. Preferably, the yarnsare polyester yarns. A knit schematic is shown in FIG. 1. The yarns forma plurality of upper level loops 101, and a plurality of lower levelloops 140. Examples of knit looped yarn fabrics include warp knitsinvolving multiple yarn ends looping in one direction andinterconnecting across in the cross direction, or weft knit fabrics withcontinuous yarns connecting cross rows as they move along. The upperloops 101 are the knit “overlaps” and the lower level loops 140 are theknit “underlaps”, or vice versa. Woven fabrics (not shown) forming loopswith multiple yarns in the warp direction inter-engaging single ormultiple yarns in the weft direction, can also be used. The looped yarnfabric has an overall thickness 104. The upper level loops or the firstyarn and the lower level loops of the second yarn are interlooped at aplurality of interlooping points 120. The interlooping points are spacedfrom each other and repeat with an interlooping distance or spacing 102.Any single loop along a given yarn in the looped yarn fabric iscontained within the interlooping distance. In one embodiment, anoptional sub-layer 105 is placed under the looped yarn fabric adjacentthe lower level loops 140. In one embodiment, the sub-layer is a lowmelting thermoplastic sheet. Cutting the looped yarn fabric results incut edges 103 of the looped yarn fabric. When the yarns in the pluralityof yarns are cut along the cut edges, the point at which a given yarn iscut can be located at one of the interlooping points or between a pairof interlooping points 120. In conventional looped yarn fabrics whereinthe interlooping points are spaced relatively far from each other, thecut edges that pass through yarns between interlooping points manifestfuzzing along the cut edges. Moreover, the fabric is relatively unstablealong its entire surface.

Referring now to FIG. 2, in one embodiment the looped yarn fabric 100 incombination with the sub-layer 105 as illustrated in FIG. 1 is uniformlycalendered with heat sufficient to melt the sub-layer 105 and inter-bondall elements of the looped yarn fabric 100. This calendering, however,reduces the original thickness 104 (FIG. 1) to a calendered thickness106, which is significantly less than the original thickness. Theresulting calendered looped yarn fabric is unacceptably stiff and lacksbody, bulk and cushion. Referring to FIG. 3, exemplary embodiments aredirected to the fabric, i.e., the looped yarn fabric 100 with anembossed micropattern extending into or disposed on a first face 112 ofthe looped yarn fabric. As illustrated, the first face contains thefirst yarn and the plurality of upper loops 101. The looped yarn fabricincludes the plurality of loops including the upper loops 101 and lowerloops 140 that are stabilized at the plurality of binding points 125spaced across the fabric by the embossed binding distances 121.

In one embodiment, the embossed micro-pattern includes a plurality ofbinding points 125 extending into the first face and binding togetheryarns. Adjacent binding points in the plurality of binding points areseparated by a binding point distance 121. The binding point distance isless than the interlooping distances 102. The resulting bonds in thebinding points can repeat at the binding point distances, which areeither regular or random, across the area of the looped yarn fabric. Thelength or amount of yarn 123 between the cut edge 103 and the nearestbinding point is less than the binding point distance. Therefore,embossing with the micro-pattern stabilizes the looped yarn fabricwithout imparting excessive stiffness or losing bulk. The cut edges areimproved as the free span between adjacent bonds in the micro-pattern issignificantly smaller than the original inter-looping point spacing. Thesurface stability and abrasion resistance of the fabric is alsoimproved.

In one embodiment, the looped yarn fabric includes the sub-layer 105 incontact with a second face 126, e.g., the lower loops, of the fabricopposite the first face. The binding points in the plurality of bindingpoints extend at least partially into the sub-layer, interbonding thesub-layer and one or more yarns.

In embodiment, the fabric embossed with the micro-pattern, either withor without the sub-layer, has an embossed thickness 111 followingapplication of the micro-pattern that is from about 40% to about 80% ofthe initial thickness 104 of the fabric. In one embodiment, the embossedthickness is at least about 60% of the initial thickness. In oneembodiment, the looped yarn fabric 100 either alone or in combinationwith the sub-layer 105 is embossed with the micro-pattern using anembossing or bonding tool (not shown) having projections correspondingto the plurality of binding points 125 formed between the looped yarnfabric and the sublayer. In one embodiment, the low-melt sub-layer isplaced on a side or surface of the looped yarn fabric opposite theembossing tool. In one embodiment, embossing is conducted at atemperature higher than the melting point of the sub-layer 105 but lowerthan the melting point of the yarns in the plurality of yarns.

In one embodiment, the sub-layer is not used, and only the looped yarnfabric is embossed with the micro-pattern. The temperature of theembossing tool is sufficiently close to the melting point of the yarnsin the looped yarn fabric to produce the plurality of bonds at thebinding points between the upper loops and the lower loops of yarns. Theembossing tool can be applied from either the top surface or the bottomsurface of the looped yarn fabric. The resulting micro-pattern loops,either with or without the sublayer, have heights and shapes that varydepending upon the location of a micro-pattern loop and bonds relativeto the original inter-engagement inter-looping points 120 of the loopsin the looped yarn fabric. Some of the newly formed loops containinterlooping yarn junctures 150, as shown.

Referring now to FIG. 4, the first face 112 of an embodiment of a loopedyarn fabric 200 with embossed micro-pattern is illustrated. The firstface includes the upper loops 201 formed by the plurality of yarns 207.The yarns and loops extend along a first direction, arrow A, or lengthof the looped yarn fabric, and adjacent yarns and loops are spaced fromeach other along a second direction, arrow B, or width of the loopedyarn fabric. The first direction is perpendicular to the seconddirection. Each loop extends between two interlooping points 220. Themicro-pattern includes a plurality of discrete binding points 225extending into the first face and binding at least the yarns in theupper loops. As illustrated, the discrete binding points are arranged asa grid of binding points. However, other arrangements of binding pointscan be used including random arrangements. In one embodiment, the gridis aligned with the first and second directions across the looped yarnfabric. Each binding point is illustrated as a circular binding point;however, other shapes of binding points can be used includingrectangular, triangular, oblong, star-shaped and x-shaped bindingpoints. In addition to discrete binding points, the binding points canbe arrangement of continuous bind lines or segments of binding lines.Adjacent binding points are separated from each other by a firstdirection binding point distance 226 and a second direction bindingpoint distance 227 perpendicular to the first direction binding pointdistance. In one embodiment, the first and second direction bindingpoints distances are less than the first direction interloopingdistances 229 and the second direction interlooping distances 230.Therefore, a distance of separation 228 between any given binding point225 and the cut edge 203 running in either the first or sectiondirection across the looping yarn fabric is less than the firstdirection interlooping distances 229 and the second directioninterlooping distances 230. This spacing also provides for stabilizingthe fabric along cut edges that run across the fabric in directionsother than parallel to the first and second directions. In oneembodiment, the fabric also includes an embossed macro-pattern separatefrom the embossed micro-pattern. The macro-pattern is defined byarrangements of a plurality of elevated areas and a plurality ofdepressed areas that establish a desired overall aesthetic in thefabric. Desired aesthetics include, for example, cross-hatchingpatterns. Adjacent elevated areas and adjacent depressed areas areseparate by a spacing interval, and this spacing interval is greaterthan the interlooping distances. Suitable methods for establishing themacro-pattern including compressing or calendering the fabric with thedesired heat and pressure using a platen containing the desiredmacro-pattern.

Referring now to FIG. 5, a macro-pattern is embossed completely into thelooped yarn fabric 100 and sub-layer 105 without the application of amicro-pattern. In one embodiment, the macro-pattern is embossed with thelooped yarn fabric and sub-layer placed against a soft surface, forexample, silicon rubber. The macro-pattern is a gross and deepmacro-pattern that repeats with a large spacing interval 114. In oneembodiment, the embossing tool temperature is less than the meltingpoint of the yarns in the looped yarn fabric and above the melting pointof the sub-layer 105. The result is a three-dimensional deep texturehaving elevated areas 113 and depressed areas 115. The loops within thedepressed areas are collapsed and inter-bonded; however, the loops inthe exposed elevated areas have exposed upper portions and are stillsusceptible to be cut free at the edges 103. The macro-pattern producesan overall thickness 116 between the elevated areas and depressed areas.

Referring now to FIG. 6, the looped yarn fabric that was pre-embossedwith the micro-pattern and stabilized as illustrated in FIG. 3. isembossed with the same macro-pattern as illustrated in FIG. 5. Themacro-pattern produces elevated areas 117 and depressed areas 118.However, the looped yarn fabric also contains the plurality of bonds atthe binding points 125 and micro-pattern loops 110 of the micro-patternembossing. The result is a macro-patterned looped yarn fabric withstable edges 103.

Referring to FIG. 7, in one embodiment, the macro-pattern 250 whenviewed from the first face of the fabric produces a cross-hatch or wovenoverall aesthetic. As illustrated in FIG. 8, this aesthetic is createdusing a embossed macro-pattern of elevated areas 251 and depressed areas252 extending at least partially or completely through the looped yarnfabric or looped yarn fabric and sublayer. The embossed micro-patternsand macro-patterns described above can be applied to different types offabrics containing yarns formed in loops extending between interloopingpoints.

Referring now to FIG. 9, in one embodiment, the fabric 300 is astitchbonded fabric containing a substrate 322. Suitable stitch-bondedsubstrates are known and available in the art. In one embodiment, thesubstrate is a low-melting layer. In another embodiment, the substratecontains un-activated low-melt adhesives. In one embodiment, the fabricincludes at least one of a first optional layer 326 and a secondoptional layer 327. In one embodiment, the first optional layer containsa low-melt adhesive and is placed on a first side of the substrate. Inone embodiment, the second optional layer contains a low-melt content isplaced on a second side of the substrate opposite the first side. In oneembodiment, both the first and second optional layers are placed on thesame side of the substrate with the first optional layer disposedbetween the substrate and the second optional layer.

The fabric contains a plurality of yarns, and each given yarn 302 in theplurality of yarns forms the plurality of upper level loops 301corresponding to the first face on a first side of the substrate and aplurality of lower level loops 340 corresponding to the second face onthe second side of the substrate. The upper level loops and lower levelloops extend between pairs of interlooping points 320. In thestitchbonded fabric, the interlooping points correspond to points ofinsertion of the yarn and the plurality of loops through the substrate.The interlooping distance 323 is the spacing between the points ofintersection in either the first direction across the fabric or thesecond direction perpendicular to the first direction.

The stitch-bonded fabric, substrate, and first and second optionallayers, if any, have an initial thickness 325. The cut ends 324 of thestitch-bonded fabric expose the yarns in the loops, which results infraying of the ends of the cut stitch-bonded fabric.

As discussed above with respect to a knit fabric and illustrated in FIG.2, the stitch-bonded fabric 300 including the substrate and any optionallow melt layers can be sufficiently calendered flat to inter-bond allloops, substrates and layers. However, stability of the stitch-bondedfabric is not achieved until the thickness of the fabric is reduced to acalendered dimension that is significantly less than the originalthickness 325, resulting in a stitch-bonded fabric that is very stiffand lacks bulk and cushion.

Referring now to FIG. 10, the stitch-bonded fabric 300 is embossed witha micro-pattern and bonded to one or more of the first and second sidesof the substrate 322 with or without using the optional first and secondlayers 326, 327 at a plurality of binding points 330. In one embodiment,the micro-pattern is embossed on at least one of the upper level loopson the first face of the fabric and the lower level loops on the secondface of the fabric. In one embodiment, the micro-pattern is embossed onboth the upper level loops on the first face of the fabric and the lowerlevel loops on the second face of the fabric. Suitable micro-patternsand methods for embossing micro-patterns are disclosed herein. In oneembodiment, separate binding points are created on the first side andthe second side of the substrate. In another embodiment, each bindingpoint passes completely through the substrate, from the first side tothe second side; therefore, a given binding point binds the yarn at agiven location on either side of the substrate.

In general, the micro-pattern repeats at intervals corresponding to thebinding point distance 329 between binding points. The binding pointdistance is less than the interlooping distances. The upper level loopsand lower level loops are compressed or collapsed, and a plurality ofnew shallower and irregular loops 344 are created. In one embodiment,the shallower and irregular loops have varying heights. The fabric has amicro-pattern embossed thickness 331 that represents a reduction of fromabout 20% to about 60% from the original thickness 325. In oneembodiment, at least 40% and preferably at least 80% of the originalthickness 325 is maintained. The first face and the second face of thefabric maintains a loopy structure, and the cut edges 324 are stable.

In one embodiment, the stitch-bonded fabric embossed and stabilized withthe micro-pattern as illustrated in FIG. 10, is subsequently embossedwith a macro-pattern (not shown). Suitable macro-patterns and methodsfor embossing with a macro-pattern are discussed herein and illustratedin FIGS. 5-8. The macro-pattern produces elevated areas and depressedareas; however, the stitch-bonded fabric also contains the plurality ofbonds 330 and micro-pattern loops 344 of the micro-pattern embossing onboth the first face and the second face. The result is a macro-patternedstitch-bonded fabric with stable elevated areas and stabilized edges.The irregular loops 344 at the elevated areas maintain their loopedtextile aesthetic. The stitch-bonded fabric has a resulting overallthickness comparable to a stitch-bonded fabric that has been embossedwith only a macro-pattern, i.e., no micro-pattern embossing.

Referring to FIG. 11, in one embodiment, the fabric is a tufted fabric400 containing a primary backing 402. Suitable primary backings areknown and available in the art. In one embodiment, the primary backingincludes low melt components. In one embodiment, the fabric includes atleast one of a first optional layer 404 and a second optional layer 405.In one embodiment, the first optional layer contains a low-melt adhesiveand is placed on a first side of the primary backing. In one embodiment,the second optional layer contains a low-melt content is placed on asecond side of the primary backing opposite the first side. In oneembodiment, both the first and second optional layers are placed on thesame side of the primary backing with the first optional layer disposedbetween the primary backing and the second optional layer.

The fabric contains a plurality of yarns, and each given yarn 406 in theplurality of yarns forms the plurality of upper level “pile” loops 401corresponding to the first face on a first side of the primary backingand a plurality of lower level “backlap” loops 408 corresponding to thesecond face on the second side of the primary backing. The upper levelloops and lower level loops extend between pairs of interlooping points420. In the tufted fabric, the interlooping points correspond to tuftingpoints of the yarn through the primary backing. Therefore, the upperlevel loops, i.e., yarn pile loops, and lower level loops, i.e.,back-lap loops, are tufted into the primary backing. The interloopingdistance 423 is the spacing between the tufting points in either thefirst direction across the fabric or the second direction perpendicularto the first direction. The tufting points have a relatively widespacing between adjacent tufting points. The fabric, as tufted, has aresulting initial thickness 415.

As discussed above with respect to the knit or woven fabric andillustrated in FIG. 2, the tufted fabric 400 including the primarybacking and any optional low melt layers can be sufficiently calenderedflat to inter-bond all loops, the primary backing and the optionallayers, and to stabilize the cut edges 424. The tufted fabric can beconventionally calendered with heat and pressure at a temperature abovethe low melt elements in the primary backing, first layer and secondlayer and lower than the melting temperature of the yarns in the yarnpile loops and back-lap loops. However, stability of the tufted fabricis not achieved until the thickness of the fabric is reduced to acalendered dimension that is significantly less than the originalthickness 415, resulting in a tufted fabric that loses its bulk,softness, and cushion and has a calendered thickness that issignificantly less than the initial thickness.

Referring to FIG. 12, the tufted fabric 400 is embossed with amicro-pattern and bonded to one or more of the first and second sides ofthe primary backing 402 and the optional first and second layers 404,405 at a plurality of binding points 430. The binding points extend intothe primary backing and interbond the primary backing and the yarns. Inone embodiment, the micro-pattern is embossed on at least one of theupper level loops on the first face of the fabric and the lower levelloops on the second face of the fabric. In one embodiment, themicro-pattern is embossed on both the upper level loops on the firstface of the fabric and the lower level loops on the second face of thefabric. Suitable micro-patterns and methods for embossing micro-patternsare disclosed herein. In one embodiment, separate binding points arecreated on the first side and the second side of the primary backing. Inanother embodiment, each binding point passes completely through theprimary backing, from the first side to the second side; therefore, agiven binding point binds the yarn at a given location on either side ofthe primary backing.

In general, the micro-pattern repeats at intervals corresponding to thebinding point distance 429 between binding points. The intervals betweenbonding points are smaller than the relatively wide spacing 423 betweenadjacent tufting points, i.e., the binding point distance is less thanthe interlooping distances 423. The upper level loops and lower levelloops are compressed and partially collapsed, and a plurality of newshallower and irregular loops 444 are created. In one embodiment, theshallower loops have varying heights and randomly varying shapes. Thefabric has a micro-pattern embossed thickness 431 that represents areduction of from about 20% to about 60% from the original thickness415. In one embodiment, at least 40% and preferably at least 80% of theoriginal thickness 415 is maintained. At least one of the first face andthe second face of the fabric maintains a loopy structure, and the cutedges 424 are stable.

In one embodiment, the tufted fabric embossed and stabilized with themicro-pattern as illustrated in FIG. 12, is subsequently embossed with amacro-pattern (not shown). Suitable macro-patterns and methods forembossing with a macro-pattern are discussed herein and illustrated inFIGS. 5-8. The macro-pattern produces elevated areas and depressedareas; however, the tufted fabric also contains the plurality of bonds430 and micro-pattern loops 444 of the micro-pattern embossing on boththe first face and the second face. The result is a macro-patternedtufted fabric with stable elevated areas and stabilized edges. The newloops 444 at the elevated areas maintain their looped textile aesthetic.The tufted fabric has a resulting overall thickness comparable to atufted fabric that has been embossed with only a macro-pattern, i.e., nomicro-pattern embossing.

Exemplary embodiments are also directed to textile composites containingthe micro-pattern and macro-pattern embossed fabrics are disclosedherein. In one embodiment, the fabric includes a plurality of yarnsforming a plurality of loops. The loops in the plurality of loops arestabilized at a plurality of interlooping points spaced across thefabric by interlooping distances between pairs of interlooping points.An embossed micro-pattern is disposed on a first face of the fabric.This embossed micro-pattern includes a plurality of binding pointsextending into the first face and binding yarns in the plurality ofyarns. Adjacent binding points in the plurality of binding points areseparated by a binding point distance that is less than the interloopingdistances. The textile composite also includes a cushioning backingattached to a second face of the fabric opposite the first face. In oneembodiment, the cushioning backing is attached using adhesive. Suitablecushioning backings are known an available in the art.

In one embodiment, the fabric is a knit fabric or a woven fabric andincludes a sub-layer in contact with the second face of the fabricopposite the first face. The binding points in the plurality of bindingpoints extend into the sub-layer and interbond the sub-layer and theyarns. In one embodiment, the fabric is a stitchbonded fabric thatincludes a substrate. The interlooping points in the plurality ofinterlooping points are points of insertion of the plurality of loopsthrough the substrate, and the interloping distance is the spacingbetween the points of intersection in either a length direction or awidth direction across the fabric. The binding points extend into thesubstrate and interbond the substrate and the yarns.

In one embodiment, the fabric is a tufted fabric having a primarybacking. The interlooping points in the plurality of interlooping pointsare tufting points through the primary backing, and the interlopingdistance is the spacing between the tufting points in either a lengthdirection or a width direction across the fabric. The binding pointsextend into the primary backing and interbond the primary backing andthe yarns. In one embodiment, the textile composite is embossed with amacro-pattern separate from the micro-pattern. The macro-pattern has aplurality of elevated areas and a plurality of depressed areas thatestablish a desired aesthetic in the textile composite. Adjacentelevated areas and adjacent depressed areas are separated by a spacinginterval, and the spacing interval is greater than the interloopingdistances.

Referring now to FIG. 13, an exemplary embodiment of a textile composite500 is illustrated. As illustrated, the fabric is a looped yarn fabric501 such as, for example, the looped yarn fabric illustrated in FIG. 1.The looped yarn fabric includes the optional sublayer 505 and a thickcushioning backing layer 502. While illustrated as a looped yarn fabricsuch as the knit fabric of FIG. 1, suitable looped yarn fabrics for theface layer include the fabric illustrated in FIGS. 9 and 11 anddescribed above. In one embodiment, the looped yarn fabric face layerincludes a top face 503 and a back face 504 opposite the top face. Inone embodiment, the looped yarn fabric face layer 501 includes anoptional internal low-melting layer 507 disposed between the top faceand the back face. In one embodiment, the internal low-melting layer isequivalent to the substrate 322 of FIG. 9 or the primary backing 402 ofFIG. 11. The looped yarn fabric can also be a woven fabric, optionallycontaining low melt yarns, partially or totally, in the weft or warpdirection, or both directions.

In one embodiment, the looped yarn fabric face layer includes a first orupper internal low-melt layer 506 and a second or lower internallow-melt layer 509 in addition to the internal low-melting layer 507.The internal low-melting layer is disposed between the upper internallow-melt layer and lower internal low-melt layer. In one embodiment, theupper and lower extra internal low-melt layers 506 and 509 areequivalent to the extra internal layers 326 or 327 of FIG. 9, or theextra internal layers 404 or 405 of FIG. 11. In embodiments where thelooped yarn fabric face layer is a knit or woven loopy fabric such asfabric 100, depicted schematically in FIG. 1, the internal low-meltinglayer 507 and the upper and lower extra internal low-melt layers 506 and509 are not included in the looped yarn fabric face layer. Suitableinternal low-melt layers include, but are not limited to, films, flatwoven fabrics, nonwoven fabrics and felts. In general, yarns form thetop face 503 and bottom face 504 of the looped yarn fabric face layer501. Suitable yarns in the fabric include, but are not limited to,polyamide or nylon, polypropylene, polyolefin, acrylic, polyester, wooland cotton. Preferably, the yarns are polyester. The internal layers,when included, are attached to and support the yarns.

In one embodiment, the yarns form a plurality of loops running along thefabric, forming the “loops or tufts” of the upper layer for a tuftedfabric, or the “overlaps” for a knit or stitch-bonded fabric, or the topand bottom of a woven fabric. The yarns also form the back layer with“back-laps” for tufted fabrics or “under-laps” for knit or stitch-bondedfabrics. The interlooping points 508 represent the points ofinter-looping of yarns or the points at which the yarns pass through thesubstrate, primary-backing or optional inner layers. These interloopingpoints form a regular pattern across the length and width, i.e., thearea, of the looped yarn fabric face layer 501. The spacing orinterlooping distance 510, in either the length or width of the loopedyarn fabric face layer 501, between any two interlooping points isreferred to as the “interval of loop repetition”.

The textile composite 500 has an initial total or accumulated thickness511 extending from the back or bottom face 512 of cushioning backinglayer 502 to the top face 503 of the looped yarn fabric face layer 501.The total thickness includes backing or cushioning layer thickness 514and face layer thickness 513. The cushioning layer thickness 514 isusually substantially greater than the face layer thickness 513. Whenthe looped yarn fabric face layer 501 does not contain the internallow-melting layer 505 or the upper and lower extra internal low-meltlayers 506 and 509, the textile composite 500 may include the separatelow-melting adhesive sub-layer 505 placed between the bottom face 504 oflooped yarn fabric face layer 501 and the backing layer 502 tofacilitate attachment of the looped yarn fabric face layer 501 to thebacking layer 502. As another option the baking layer 502 may containsufficient low-melting polymer to achieve bonding without a separateadhesive layer 505.

Referring now to FIG. 14, the textile composite 500 of FIG. 13 isdirectly embossed with a macro-pattern. The looped yarn fabric facelayer 501 and the backing layer 502 pre-assembled as illustrated in FIG.13 are embossed with the macro-pattern to produce elevated areas 515 anddepressed areas 516 and a given large spacing interval 517 betweenadjacent elevated areas of the macro-pattern. The elevated areas 515 inthe macro-pattern are not stabilized. When cut edges 518 are formed inthe textile composite 500, these cut edges can pass through the spacing510 between adjacent points of attachment 508. Since the yarns runningalong the cut edge are not sufficiently anchored to each other or to anintermediate layer, unraveling and fuzzing can occur, and the surfacestability and abrasion resistance overall may be unsatisfactory.

Referring now to FIGS. 15 and 16, exemplary embodiments of the textilecomposite 500 use an embossed micro-pattern either alone or incombination with the embossed macro-pattern to alleviate wear, abrasion,deterioration of the integrity of the textile composite and unravelingand fuzzing within the attachment intervals, at cut edges. In oneembodiment, the micro-pattern is embossed on the combined face fabriclayer and backing layer, creating a textile composite having a loopy butrelatively flat surface. In one embodiment, the textile composite 500 isembossed with a heated tool (not shown) having projections spaced withat intervals in accordance with the binding point distance 520 applieddirectly from the top face 503, to produce a plurality of bonds 522 thatrepeat at regular or random intervals defined by the binding pointdistance 520. These intervals are smaller than the interloopingdistances 510 between interlooping points 508. The looping yarns aretransformed into shallower irregular micro-pattern loops 524 with themicro-pattern repeating at intervals defined by the binding pointsdistances 520 between binding points 522. The micro-pattern loops haverandomly varying shapes. In one embodiment, the binding points extendinto the sub-layer 505. In another embodiment, the binding points extendinto the backing layer 502. The yarns in the fabric face layer arestabilized in the fabric face layer 501 and are attached to thesub-layer and backing. In addition, any substrate, primary-backing oroptional low melt layers are also attached to the backing. The resultingtextile composite is stable at the cut edges 518.

Referring to FIG. 16, the textile composite 500 embossed with themicro-pattern is subsequently embossed with the macro-pattern. Theembossed micro-pattern stabilizes the yarns ion the fabric, and theembossed macro-pattern creates a desired aesthetic face texture andproduces properties in the textile composite such as slip resistance andface cushion. The composite 500 is re-embossed with a coarsermacro-pattern having elevated areas 515 separated by the large spacinginterval 517. The micro-pattern modifies but does not eliminate thedesired loop aesthetics and feel, which are also retained after thesecond embossing or re-embossing with the macro-pattern.

Suitable methods for applying any of the micro-patterns andmacro-patterns discussed herein include, but are not limited to, using aheated embossing roll or plate, simultaneously activating the low-meltlayers and bonding the face fabric to the substrate. A soft back up toolis not required if the backing is sufficiently deep and conformable. Inone embodiment the micro-embossed fabrics shown in FIG. 3, 10 or 12 areused as face layers in the textile composite, which is then embossedwith the macro-pattern and simultaneously attached to the cushioningbacking.

Exemplary embodiments are also directed to methods for stabilizingfabrics and textile composites containing those fabrics. A fabric iscreated that contains a plurality of yarns forming a plurality of loops.The loops in the plurality of loops are stabilized at a plurality ofinterlooping points spaced across the fabric by interlooping distancesbetween pairs of interlooping points. A first face of the fabric isembossed with a micro-pattern having a plurality of binding pointsextending into the first face and binding yarns in the plurality ofyarns. Adjacent binding points in the plurality of binding points areseparated by a binding point distance, and the binding point distance isless than the interlooping distances.

In one embodiment, the fabric containing the micro-pattern is embossedwith a macro-pattern separate from the micro-pattern. The macro-patternproduces a plurality of elevated areas and a plurality of depressedareas that establish a desired aesthetic in the fabric. Adjacentelevated areas and adjacent depressed areas are separated by a spacinginterval, and the spacing interval greater than the interloopingdistances.

Referring now to FIGS. 17 and 18, exemplary embodiments of methods forstabilizing a textile fabric formed with looping yarns, or a compositehaving a face fabric formed with looping yarns are illustrated. FIG. 17illustrates a method applicable to looped fabrics and compositescontaining looped fabrics without a low-melting inner layer. FIG. 18illustrates a method applicable to looped fabrics and compositescontaining looped fabrics formed with an inner low melting layer. Allembodiments form a textile fabric with inter-engaging yarn loops, i.e.,interlooping yarns.

Referring to FIG. 17, a method 850 for creating and stabilizing loopedfabrics or composites containing looped fabric face layers isillustrated. A looped fabric containing interlooping loops is formed800. Suitable looped fabrics include, but are not limited to, wovenfabrics and knit or tufted fabrics. In one embodiment, the looped fabricis formed without an intermediate internal layer. In one embodiment, atleast one low melt sheet, e.g., a sub-layer, is placed under the loopedfabric 801. The looped yarn fabric can be stabilized alone or as part ofa textile composite. Therefore, a determination is made regardingwhether or not additional layers such as a cushioning backing layer areto be combined with the looped fabric and any low melt layer 851. If abacking layer is to be added, then the backing layer is placedunderneath the low melt layer 802 such any low melt sub-layer is betweenthe cushioning backing layer and the looped fabric face layer.

If no backing layer is to be added or after the backing layer is added,the looped fabric and low melt layer or the textile composite containingthe looped fabric is embossed with a micro-pattern. Suitablemicro-patterns and methods for embossing micro-patterns are discussedherein. Embossing with a micro-pattern yields a stabilized relativelyflat micro-textured looped fabric or a textile composite with a flatmicro-patterned and micro-textured looped fabric face layer.

A determination is then made regarding whether the micro-patternedlooped fabric or the micro-pattern textile composite is to be embossedwith a macro-pattern 804 to yield a three-dimensional fabric or atextile composite with a three-dimensional fabric face layer. Ifembossing with the macro-pattern is to be done, then the looped fabricwith the micro-pattern or the textile composite with the micro-patternof step is embossed with the desired macro-pattern 805. Suitablemacro-patterns and methods for embossing macro-patterns are disclosedherein. Stabilized textured surfaces are then obtained 806. In summary,embossing with a micro-pattern yields flat looped fabrics stabilizedwith the micro-pattern or textile composites with looped face fabricsstabilized by the micro-pattern, whereas embossing with themacro-pattern yields three-dimensional looped fabrics pre-stabilizedwith micro-embossing and converted into a three-dimensional structure bymacro-embossing or textile composites having looped face fabricspre-stabilized by micro-embossing and embossed with a three-dimensionalface contour.

Referring now to FIG. 18, a method 900 for creating and stabilizing afabric with loops inserted into an inner layer or textile compositescontaining a fabric with loops inserted into an inner layer isillustrated. A fabric with loops inserted into an inner layer is formed901 by yarns penetrating through a low-melt internal layer at regularintervals, e.g., a stitch-bonded fabric formed with an inner substratelayer or a tufted fabric formed with an internal primary-backing layer.A determination is then made regarding whether to add a cushioningbacking layer 902 if the fabric is going to be part of a textilecomposite. If the backing layer is to be added, an adhesive layer isplaced under the fabric 904 and a backing layer is placed under theadhesive layer 906.

The fabric or the textile composite is embossed with a micro-pattern.Suitable micro-patterns and methods for embossing with micro-patternsare disclosed herein. In one embodiment, embossing with themicro-pattern is conducted at a temperature higher than the meltingtemperature of the inner low-melt layer. Embossing with themicro-pattern yields a relatively flat stable fabric with loops insertedinto an inner layer with modified loops on the surface.

A determination is then made regarding whether a coarser macro-patternis to be embossed on the micro-pattern stabilized composite or themicro-pattern stabilized fabric 910. If a macro-pattern is to be formed,then the fabric or the textile composite is embossed with amacro-pattern 912. Suitable macro-patterns and method for embossing amacro-pattern are discussed herein. Therefore, stabilized texturedsurfaces are obtained 914. In summary embossing with a micro-patternyields micro-embossed stabilized looped fabrics or textile compositeswith face layers containing stabilized loop fabrics, whereas embossingthe macro-pattern yields there-dimensional looped fabrics stabilizedwith micro-embossing and converted three-dimensional structures formedby macro embossing or textile composites with pre-stabilized loopedfabrics embossed with a three-dimensional texture.

This written description uses examples of the subject matter disclosedto enable any person skilled in the art to practice the same, includingmaking and using any devices or systems and performing any incorporatedmethods. The patentable scope of the subject matter is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims.

What is claimed is:
 1. A fabric comprising: a plurality of yarns forminga plurality of loops, the plurality of loops interconnected at aplurality of interlooping points spaced across the fabric byinterlooping distances between pairs of interlooping points; and anembossed micro-pattern disposed on a first face of the fabric, theembossed micro-pattern comprising a plurality of binding pointsextending into the first face and binding the yarns in the plurality ofyarns, adjacent binding points in the plurality of binding pointsseparated by a binding point distance, the binding point distance lessthan the interlooping distances.
 2. The fabric of claim 1, wherein thefabric comprises a knit fabric or a woven fabric.
 3. The fabric of claim1, further comprising a sub-layer in contact with a second face of thefabric opposite the first face, the plurality of binding pointsextending into the sub-layer and interbonding the sub-layer and theyarns.
 4. The fabric of claim 3, wherein: the fabric comprises astitchbonded fabric comprising a substrate, the plurality ofinterlooping points comprising points of insertion of the plurality ofloops into the substrate, the interloping distance comprising spacingbetween the points of intersection in either a first direction acrossthe fabric or a second direction perpendicular to the first direction;and the binding points extend into the substrate and interbond thesubstrate and the yarns.
 5. The fabric of claim 4, wherein the substratecomprises a low melt material.
 6. The fabric of claim 4, wherein thefabric further comprises at least one additional low melt layer disposedbetween the substrate and at least one of the first face a second faceopposite the first face.
 7. The fabric of claim 1, wherein: the fabriccomprises a tufted fabric comprising a primary backing, the plurality ofinterlooping points comprising tufting points through the primarybacking, the interlooping distance comprising spacing between thetufting points in either a length direction or a width direction acrossthe fabric; and the binding points extend into the primary backing andinterbond the primary backing and the yarns.
 8. The fabric of claim 7,wherein the primary backing comprises low melt components.
 9. The fabricof claim 7, wherein the fabric further comprises at least one additionallow melt layer disposed between the primary backing and at least one ofthe first face a second face opposite the first face.
 10. The fabric ofclaim 1, wherein the fabric further comprises an embossed macro-patternseparate from the micro-pattern, the macro-pattern comprising aplurality of elevated areas and a plurality of depressed areas thatestablish a desired aesthetic in the fabric, adjacent elevated areas andadjacent depressed areas are separate by a spacing interval, the spacinginterval greater than the interlooping distances.
 11. The fabric ofclaim 1, wherein the fabric comprises an initial thickness and anembossed thickness following application of the micro-embossed pattern,the embossed thickness comprising from about 40% to about 80% of theinitial thickness.
 12. The fabric of claim 1, wherein the fabriccomprises an initial thickness and an embossed thickness followingapplication of the micro-embossed pattern, the embossed thicknesscomprising at least about 60% of the initial thickness.
 13. The fabricof claim 1, wherein the plurality of yarns comprises polyester.
 14. Atextile composite comprising: a fabric comprising: a plurality of yarnsforming a plurality of loops, the plurality of loops interconnected at aplurality of interlooping points spaced across the fabric byinterlooping distances between pairs of interlooping points; and anembossed micro-pattern disposed on a first face of the fabric, theembossed micro-pattern comprising a plurality of binding pointsextending into the first face and binding yarns in the plurality ofyarns, adjacent binding points in the plurality of binding pointsseparated by a binding point distance, the binding point distance lessthan the interlooping distances; and a cushioning backing attached to asecond face of the fabric opposite the first face.
 15. The textilecomposite of claim 14, wherein: the fabric comprises a knit fabric or awoven fabric; and the fabric further comprises a sub-layer in contactwith the second face of the fabric, the plurality of binding pointsextending into the sub-layer and interbonding the sub-layer and theyarns.
 16. The textile composite of claim 14, wherein: the fabriccomprises a stitchbonded fabric comprising a substrate, the plurality ofinterlooping points comprising points of insertion of the plurality ofloops through the substrate, the interloping distance comprising spacingbetween the points of intersection in either a length direction or awidth direction across the fabric; and the binding points extend intothe substrate and interbond the substrate and the yarns.
 17. The textilecomposite of claim 14, wherein: the fabric comprises a tufted fabriccomprising a primary backing, the plurality of interlooping pointscomprising tufting points through the primary backing, the interlopingdistance comprising spacing between the tufting points in either alength direction or a width direction across the fabric; and the bindingpoints extend into the primary backing and interbond the primary backingand the yarns.
 18. The textile composite of claim 14, wherein thetextile composite further comprises an embossed macro-pattern separatefrom the micro-pattern, the macro-pattern comprising a plurality ofelevated areas and a plurality of depressed areas that establish adesired aesthetic in the textile composite, adjacent elevated areas andadjacent depressed areas are separate by a spacing interval, the spacinginterval greater than the interlooping distances.
 19. A method forstabilizing a fabric, the method comprising: forming a fabric comprisinga plurality of yarns forming a plurality of loops, the plurality ofloops interconnected at a plurality of interlooping points spaced acrossthe fabric by interlooping distances between pairs of interloopingpoints; and embossing a first face of the fabric with a micro-patterncomprising a plurality of binding points extending into the first faceand binding yarns in the plurality of yarns, adjacent binding points inthe plurality of binding points separated by a binding point distance,the binding point distance less than the interlooping distances.
 20. Themethod of claim 19, wherein the method further comprises embossing thefabric containing the micro-pattern with a macro-pattern separate fromthe micro-pattern, the macro-pattern comprising a plurality of elevatedareas and a plurality of depressed areas that establish a desiredaesthetic in the fabric, adjacent elevated areas and adjacent depressedareas are separated by a spacing interval, the spacing interval greaterthan the interlooping distances.